U.S. patent application number 16/708408 was filed with the patent office on 2020-06-18 for pivotable flipper for thermoforming apparatus for forming undercuts in packaging.
The applicant listed for this patent is Portage Plastics Corporation. Invention is credited to Anthony Domerchie, Christopher Meier, Julio C. Mendoza.
Application Number | 20200189173 16/708408 |
Document ID | / |
Family ID | 71073246 |
Filed Date | 2020-06-18 |
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United States Patent
Application |
20200189173 |
Kind Code |
A1 |
Mendoza; Julio C. ; et
al. |
June 18, 2020 |
Pivotable Flipper for Thermoforming Apparatus for Forming Undercuts
in Packaging
Abstract
A flipper assembly that can be used with a package-producing
mold, for instance, a mold that is used during thermoforming
procedures. The flipper assembly includes a base mounted to the
mold, a flipper arm pivotably connected to the base between a first
position where the arm is substantially perpendicular to the height
of the base and a second position where the arm is substantially
parallel to the height of the base, and a spring mounted to the
base and the flipper arm. During the thermoforming process, the
flipper arm forms an undercut of finger into the package, which
improves the stability and strength of the package. The flipper arm
is moved between first and second positions based on linear
extension and retraction of the spring.
Inventors: |
Mendoza; Julio C.;
(Brownsville, TX) ; Meier; Christopher; (Portage,
WI) ; Domerchie; Anthony; (Green Oaks, IL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Portage Plastics Corporation |
Portage |
WI |
US |
|
|
Family ID: |
71073246 |
Appl. No.: |
16/708408 |
Filed: |
December 9, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62743220 |
Oct 9, 2018 |
|
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B29C 51/445 20130101;
B29C 51/20 20130101; B29C 51/38 20130101 |
International
Class: |
B29C 51/44 20060101
B29C051/44; B29C 51/38 20060101 B29C051/38; B29C 51/20 20060101
B29C051/20 |
Claims
1. A flipper assembly for use with a thermoforming mold comprising:
a base mounted to the mold; and a flipper arm having a
three-dimensionally contoured feature molding surface configured
for molding a feature into a molded component formed in the
thermoforming mold, the flipper arm connected by a pivot to the
base and configured for pivotable movement between a molding
position and a molded component release facilitating position
disposed distal from the molding position.
2. The flipper assembly of claim 1, wherein the flipper arm is
disposed in a generally horizontal position when disposed in the
molding position and configured to pivot upwardly towards a molded
component release facilitating position during demolding of a
molded component formed in the thermoforming mold.
3. The flipper assembly of claim 2, wherein the flipper arm is
configured with a center of gravity disposed forwardly of the pivot
providing a flipper arm return force vector configured for urging
the flipper arm to return to the molding position when the flipper
arm is disposed in a molded component release facilitating
position.
4. The flipper assembly of claim 3, further comprising a flipper
arm return force biasing element extending between the flipper arm
and the base configured to provide another force vector urging the
flipper arm to return to the molding position when the flipper arm
is disposed in a molded component release facilitating
position.
5. The flipper assembly of claim 4, wherein the flipper arm return
force biasing element comprises a flipper arm return spring
configured to return the flipper arm to the molding position.
6. The flipper assembly of claim 5, wherein the flipper arm return
spring comprises an elongate coil spring operatively coupled in
tension to the flipper arm and base.
7. The flipper assembly of claim 6, wherein the flipper arm return
spring is housed within the flipper arm and the base; wherein the
flipper arm has a spring receiving conduit formed therein in which
one portion of the flipper arm return spring is received therein;
and wherein the base has a spring receiving conduit formed therein
in which another portion of the flipper arm return spring is
received therein.
8. The flipper assembly of claim 7, further comprising a first
spring anchor carried by the flipper arm to which one end of the
flipper arm return spring is attached, a second spring anchor
carried by the base to which an opposite end of the flipper arm is
attached, and wherein the flipper arm return spring contacts no
portion of the flipper arm and base when the flipper arm is pivoted
between the molding position and a molded component release
facilitating position.
9. The flipper assembly of claim 8, wherein the pivot comprises an
elongate cylindrical pin pivotably connecting the flipper arm to
the base, first spring anchor comprises an elongate generally
cylindrical pin carried by the flipper arm, and second spring
anchor comprises an elongate generally cylindrical pin carried by
the base.
10. The flipper assembly of claim 1, wherein the
three-dimensionally contoured feature molding surface projects
outwardly from part of the flipper arm and from the base when the
flipper arm is disposed in the molding position.
11. The flipper assembly of claim 10, wherein the
three-dimensionally contoured feature molding surface is configured
to form an undercut in a molded component formed in the
thermoforming mold.
12. The flipper assembly of claim 12, wherein the
three-dimensionally contoured feature molding surface is configured
to form a finger or flipper.
13. The flipper assembly of claim 1, wherein the flipper arm is
gravity actuated between the molded position and a molded component
release facilitating position disposed distal from the molding
position.
14. The flipper assembly of claim 13, wherein gravity acting on a
center of gravity of the flipper arm produces a gravity actuated
return force on the flipper arm opposing pivoting of the flipper
arm away from the molded position.
15. The flipper assembly of claim 1, further comprising a biasing
element that actuates the flipper arm between the molded position
and a molded component release facilitating position disposed
distal from the molding position.
16. The flipper assembly of claim 14, wherein the biasing element
produces a biasing element actuated return force on the flipper arm
opposing pivoting of the flipper arm away from the molded
position.
17. The flipper assembly of claim 17, wherein the biasing element
comprises an elongate coil spring operatively connecting the
flipper arm to the base.
18. A flipper assembly for use with a thermoforming mold
comprising: a base mounted to the mold; a flipper arm pivotably
connected to the base; and a spring having a first end attached to
the base and a second end attached to the flipper arm; wherein a
sheet is pressed against the base and the flipper arm when the
sheet is formed into the package; and wherein the flipper arm is
pivoted relative to the base after a sheet is formed into a
package.
19. The flipper assembly of claim 18, wherein the arm is pivotable
between: a first position where the arm is substantially
perpendicular to the height of the base; and a second position
where the arm is substantially parallel to the height of the
base.
20. The flipper assembly of claim 19, wherein the flipper arm is
moved from the first position to the second position after the
thermoforming process; and wherein the flipper arm is returned to
the first position after the package has been disengaged from the
flipper arm by the spring.
21. The flipper assembly of claim 20, wherein the spring extends in
a purely linear fashion between the first position to the second
position.
22. The flipper assembly of claim 20, wherein the spring retracts
in a purely linear fashion between the second position to the first
position.
23. The flipper assembly of claim 18, wherein the flipper arm forms
a finger in an undercut that is formed in the sheet.
24. The flipper assembly of claim 18, further comprising a first
pin extending through a portion of the base and the flipper arm;
wherein the flipper arm pivots about the first pin when the package
is disengaged from the flipper arm.
25. The flipper assembly of claim 24, further comprising: a second
pin extending through a portion of the base; a third pin extending
through a portion of the flipper arm; and wherein the second pin
extends through the first end of the spring; and wherein the third
pin extends through the second end of the spring.
26. The flipper assembly of claim 18, wherein the flipper arm
rotates relative to the base when the package is removed.
27. The flipper assembly of claim 18, wherein the base further
comprises: a front side; and at least one ridge extending from the
first side; wherein the at least one ridge forms ridges in the
package; and wherein the flipper arm comprises a finger extending
therefrom.
28. The flipper assembly of claim 27, wherein the sheet is
compressed against the at least one ridge and the finger during the
thermoforming process.
29. A method of thermoforming a sheet into a package comprising the
steps of: placing a sheet of material into a mold having a flipper
assembly mounted therein, wherein the flipper assembly comprises: a
base with a front wall; a flipper arm that is pivotably connected
to the mold between: a retracted position; and a deployed position;
and a spring with a first end mounted to the base and a second end
mounted to the flipper arm; wherein the sheet rests on the flipper
arm; applying a pressure differential to create a suction of the
sheet against the flipper assembly; forming a package against the
front wall and the flipper arm, wherein an undercut is formed where
the sheet is pressed against a front edge of the flipper arm;
rotating the flipper arm from the retracted position to the
deployed position to release the package from the flipper assembly
without distorting the package; and rotating the flipper arm to the
retracted position by the spring.
30. The method of claim 29, wherein the base and the flipper arm
constitute a cross-sectional profile; and wherein the shape of the
package is substantially the same shape as the cross-sectional
profile.
31. The method of claim 29, further comprising the steps of:
extending the spring in a linear fashion when the flipper arm is
pivoted from the retracted position to the deployed position; and
retracting the spring in a linear fashion when the flipper arm is
pivoted from the deployed position to the retracted position.
32. A flipper assembly for use with a package-producing mold
comprising: a base mounted to the mold; a flipper arm pivotably
connected to the base; a spring having a first end and a second
end; a first pin extending through the first end of the spring and
the base; a second pin extending through the second end of the
spring and the flipper arm; wherein a sheet is pressed against the
base and the flipper arm when the sheet is formed into the package;
and wherein the flipper arm is pivoted relative to the base after a
sheet is formed into a package.
33. The flipper assembly of claim 32, wherein the first pin and the
second pin are vertically offset from one another.
34. The flipper assembly of claim 33, wherein the spring extends
and retracts between the first pin and the second pin in a purely
linear fashion.
35. The flipper assembly of claim 34, wherein the flipper arm is
pivotable between: a first position where the arm is substantially
perpendicular to the height of the base; and a second position
where the arm is substantially parallel to the height of the
base.
36. The flipper assembly of claim 18, wherein the flipper arm is
moved from the first position to the second position after the
thermoforming process; and wherein the flipper arm is returned to
the first position after the package has been disengaged from the
flipper arm by the spring.
37. The flipper assembly of claim 33, further comprising a third
pin extending through the base and the flipper arm; wherein the
third pin serves as a pivot point of the flipper arm.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to U.S. Provisional
Application No. 62/743,220, filed on Oct. 9, 2018, the entire
contents of which are hereby expressly incorporated by reference
into this application.
FIELD
[0002] The present invention is directed to a flipper that is
pivotable relative to a thermoforming mold where the flipper is
configured to form an undercut, such as a finger, in a sheet that
is being thermoformed into a thermoformed part, such as a
thermoformed package.
BACKGROUND
[0003] Many different types of thermoformed parts and components,
including packages, can be manufactured quickly, easily, and
affordably using thermoforming practices. To do so, a sheet of
thermoformable plastic material is heated until the sheet is
pliable. During or after heating, the pliable sheet can be pressed,
stretched, or sucked using a vacuum into a three-dimensionally
contoured of a mold. As a result, the sheet takes the shape of the
three-dimensionally contoured cavity formed in the mold, resulting
in a three-dimensionally shaped part, e.g., three-dimensionally
shaped package, which is similar in shape to the three-dimensional
shape of the mold cavity. After being formed into the desired
three-dimensional shape, the three-dimensional shape of the part,
e.g., package, is set by cooling or allowing it to cool thereby
fixing its shape memory after thermoforming in a manner that
retains the three-dimensional shape of the part. Depending on the
desired characteristics of the part, e.g., package, can be
thermoformed from relatively thin sheets having thicknesses ranging
between 0.060-0.375 inches or between 1.5-9.5 mm composed of a
variety of materials, such as acrylonitrile butadiene styrene
(ABS), polycarbonate, high-density polyethylene, polypropylene,
polyvinyl chloride (PVC), polyethylene terephthalate (PET or PETG),
or styrene.
[0004] In many industries, more durable thermoformed packages are
desired or required. For instance, many windshield wiper blades are
packaged, transported and displayed for retail sale in thermoformed
packages. Windshield wiper blades oftentimes are manufactured with
a substantially continuous curve, e.g., pre-curved beam-type wiper
blades, which results in more uniform contact with a vehicle
windshield during wiper operation to improve wiping efficiency. Due
to the significant curvature of these types of windshield wiper
blades, a thermoformed wiper blade package will need to possess
significant strength, including good structural rigidity, in order
to hold the pre-curved wiper blade in place. This is especially
true given the fact that pre-curved beam wiper blades are typically
held by the package in a partially or substantially straightened
condition to minimize package volume and maximize retail display
package density. In order to hold such a pre-curved beam wiper
blade in place in a partially or substantially straightened
condition, particularly where the thermoformed package is
reclosable, the associated pre-curved beam wiper blade packaging
should have features that increase the strength and rigidity of
such reclosable packaging and which help retain the reclosable
packaging in the closed condition.
[0005] As a result, many thermoformed packages, not just reclosable
wiper blade packages, include a variety of features molded into the
sheet during thermoforming in order to improve the overall strength
of the package, especially in areas prone to failure, depending on
the contents of the packaging. For instance, many types of packages
include features formed during thermoforming that protrude or
extend inwardly from various top, bottom, or side walls of the
package whose function can vary. Such protruding thermoformed
features can be configured not only to improve package strength or
rigidity but also to help retain an article in a recessed
article-holding compartment of the package, including while the
package is closed.
[0006] Modern designs of thermoformed parts, including thermoformed
packages, increasingly include deeper, longer and ever more
aggressive protruding features called undercuts, which typically
require attachment of various components to the mold that have a
three-dimensionally contoured molding surface disposed in the mold
cavity that imparts a like three-dimensional shape to the part of
the sheet drawn against it during thermoforming. More extreme types
of undercuts can take the form of larger, longer, stronger, and
more rigid fingers configured to more securely engage and hold an
article within a recessed article-retaining cavity of the package
that can also be configured to better resist flexing of the
package. In the case of wiper blade packages designed to hold
pre-curved beam wiper blades, it is common to thermoform multiple
sets of fingers into a single package that extend into the
blade-holding compartment and configured not only provide snap-fit
engagement with the pre-curved beam of a wiper blade placed in the
compartment, but which also make the package more rigid to prevent
a cover of the package from coming loose or popping off.
[0007] In the past, flipper assemblies have been attached to
thermoforming molds that each have a flipper movable relative to
the mold and which has a three dimensionally contoured molding
surface configured to form a finger in a thermoformed parts, such
as thermoformed packaging, e.g., reclosable packaging designed to
hold pre-curved beam wiper blades. It has been learned that the
more extreme the fingers and undercuts that can be formed into a
package, the stronger the overall package will be and the less
prone the package will be to popping open.
[0008] Flipper assemblies employed in the past to form such fingers
and other types of more aggressive undercuts are in the form of a
cartridge that is a base of the assembly that is configured to be
removably attached to a mold of a thermoforming apparatus. The
flipper assembly cartridge or base, e.g., base, has a movable
flipper that protrudes outwardly into the mold cavity and which has
a three-dimensionally contoured molding face against which part of
the sheet is urged and complementarily conforms to form an
undercut, preferably a finger, in the part, e.g., package, being
thermoformed. The flipper typically is pivotably attached by a pin
enabling the flipper to rotate about a pivot formed by the pin,
e.g., pivot pin, between a first position or molding position where
its molding face is ready for forming in the mold cavity and a
second position or a molded component release facilitating
position, e.g. part-demolding position, disposed away from the
molding position that facilitates removal of a finished
thermoformed part from the mold. These flipper assemblies employ a
coil spring that extends between the base and flipper to help urge
the flipper to pivot back to the molding position after the
thermoformed part, e.g., thermoformed package, becomes completely
disengaged from the flipper during part demolding.
[0009] In the past, such flipper assemblies have suffered from
numerous problems and drawbacks, which were magnified by deeper and
more aggressive flipper assembly designs increasingly coming into
use. One known problem is that over the course of many
thermoforming cycles, the flipper return spring becomes
increasingly less able to produce enough force to rotate the
flipper back to the molding position after demolding of a
thermoformed part is completed. Over time, overstretching of the
return spring occurs that reduces the ability of the spring to
return the flipper back to the molding position because this
overstretching disadvantageously reduces the amount of return
spring force the spring can generate. When the flipper fails to
return back to the molding position before the beginning of the
next thermoforming cycle, the next part will be defectively
thermoformed because the finger or undercut will not be properly or
completely formed. This not only results in monetary losses in the
form of an increase in the number of defectively thermoformed
parts, but it also requires more frequent and costly thermoforming
apparatus downtime to more frequently change the return spring with
a new one possessing enough return force to ensure the flipper once
again returns to the molding position.
[0010] It has also been learned that the orientation and
configuration of the flipper of the flipper assembly in the
thermoforming mold cavity can also adversely impact finger and
undercut formation in a similar manner. While a stronger return
spring may be required, some orientations and configurations have
proven to be less reliable than others. While use of a stronger
spring can sometimes help, it still does not help prevent premature
overstretching of the spring such that upside down flipper assembly
orientations and configurations where the flipper has an unusual,
e.g., non-symmetrical, shape or is bulky also are prone to
increased thermoformed part defect rates and undesirably more
frequent return spring replacement.
[0011] Accordingly, there is a need for an improved mechanism used
to form fingers and other undercuts which readily moves out of the
way during removal of thermoformed parts, such as during
thermoforming of wiper blade packaging, to facilitate part removal
and which reliably and consistently homes back to the molding
position. There also is a need for an improved mechanism which can
be used to form fingers and other undercuts using a pivotable
flipper that is biased between a first home or molding position and
a second molded part release position to allow the thermoformed
part, e.g., thermoformed wiper blade package, to be removed without
damaging the thermoformed part, after which the pivotable flipper
is returned to the home or molding position.
SUMMARY
[0012] The present invention helps to overcome these issues by
providing a flipper assembly that can be used with a thermoforming
mold to create high-quality, strong thermoformed parts, preferably
thermoformed packages, which have extreme undercuts or fingers,
while allowing for the easy removal of the part, preferably
package, once the thermoforming process has been completed. In a
preferred embodiment and method, the improved flipper assembly of
the present invention is used in the making of thermoformed wiper
blade packages, which preferably are of reclosable clamshell
package construction.
[0013] To do so, the flipper assembly includes a base, a flipper
arm, and can also employ a flipper arm biasing element that
preferably is a spring. In a preferred embodiment, a flipper
assembly constructed in accordance with the present invention
employs a flipper arm biasing element, which preferably is or
includes a spring in tension, configured to rotatively return the
flipper arm to a home or molding position after removal of a
thermoformed part from the cavity of a thermoforming mold. The base
is configured to be mounted to the mold. The flipper arm is
pivotably connected to the base about a pivot point and oriented so
it is at least partially disposed in the mold cavity when in its
home or molding position. The spring has a first end that is
attached to the base and a second end attached to the flipper arm.
The spring is connected in tension and configured to allow the
flipper arm to pivot about the pivot point between the home or
molding position, and a molded part release position disposed from
the home or molding position during thermoforming apparatus
operation.
[0014] During the thermoforming process, a sheet of thermoformable
material, preferably thermoformable plastic, is pressed or sucked
by vacuum into a three-dimensionally contoured cavity of a mold of
a thermoforming apparatus thereby pressing or sucking the sheet
against a portion of the base and the flipper arm. During
thermoforming, the flipper arm is disposed in its home or molding
position projecting into the cavity of the mold so a portion of the
thermoformable material being drawn into the mold cavity by vacuum
is urged against the flipper arm thereby conforming it to a
three-dimensional shape of the flipper arm. This results in the
formation of a substantially complementarily three-dimensionally
contoured finger or another undercut shape or configuration in a
portion of the package. Once the thermoforming process is
completed, the flipper arm is pivoted relative to the base away
from the home or molding position, which allows the package to be
disengaged from the flipper assembly without damaging the package
about the finger and/or undercut. The flipper arm is pivoted by the
portion of the thermoformed package in contact therewith away from
the home or molding position by demolding of the package from the
mold.
[0015] For instance, the flipper arm can be pivoted between a first
position, preferably the home or molding position, where the
flipper arm is substantially perpendicular to the height of the
base and a second position, preferably a molded part release
facilitating position during demolding, where the flipper arm is
substantially parallel to the height of the base. The flipper arm
can be moved from the first position to the second position after
the thermoforming process and then from the second position to the
first position by the spring after the package has been disengaged
from the flipper arm. To effectuate the pivoting action of the
flipper arm, a first pin can extend through a portion of the base
and the flipper arm such that the flipper arm is pivoted about the
first pin when the package is disengaged form the flipper arm.
Additionally, a second pin can extend through a portion of the base
and a third pin can extend through a portion of the flipper arm.
The second pin can extend through the first end of the spring and
the third pin can extend through the second end of the spring.
Alternatively, another mechanical biasing element can be used that
mechanically couples the flipper arm to the base in a manner that
automatically returns the flipper arm from the second position to
the first position after the package is disengaged from the flipper
arm during demolding of the package. Further still, the flipper
assembly can include a front side having at least one ridge. When
the package is thermoformed, the sheet of plastic can be pressed
against the at least one ridge producing a finger or undercut
substantially conforming to sheet the three-dimensional shape of
the flipper assembly, including the at least one ridge, to impart
added rigidity to the package.
[0016] In one aspect, the present invention is directed to a
flipper assembly and method of making a flipper assembly where the
pivot point and center of gravity are configured to minimize the
magnitude of the force required to return the flipper arm back to
the home or molding position after it has been displaced away
therefrom to or towards a molded part release position. More
specifically, the center of gravity of the flipper arm may be
located so as to minimize the vector force required to return the
flipper arm to the home or molded position. This can be achieved,
for instance, by locating the center of gravity in close proximity
to the pivot point of the flipper arm. In another aspect, the
present invention is directed to a flipper assembly and method of
making a flipper assembly configured to optimize placement of the
pivot point and center of gravity of the flipper arm based on at
least one of the position and orientation of the flipper assembly
and/or flipper arm in the mold cavity.
[0017] In yet another aspect, the spring may be mounted to the base
and the flipper arm in such a way that the spring stretches and
contracts in a linear fashion. The combination of the linear
movement of the spring and the location of the center of gravity of
the flipper arm help to minimize the amount of force required to
return the flipper arm to the home or molded position. Further
still, in another aspect of the invention, the flipper arm can be
specifically located to utilize gravitational forces to further
help return the flipper arm to the home or molded position.
[0018] The present invention also is directed to an
undercut-molding flipper assembly having a preferred form of a
modular "plug and play" cartridge that includes a cartridge base
that carries a flipper arm with a three-dimensionally contoured
molded feature forming surface, e.g., nose, which is pivotable
between a molding position, e.g., operating position, and a molded
component release facilitating position disposed distal from the
molding position. The flipper arm is pivotally mounted to the base
by a pivot with a center of gravity, Cg, of the flipper arm
disposed forwardly of the pivot such that gravity acting on the
flipper arm, when the flipper arm is disposed in a molded component
release facilitating position, produces a return force that returns
or facilitates return of the flipper arm to the molding
position.
[0019] The flipper assembly can have and preferably includes a
flipper arm return biasing element that more preferably is an
elongate coil spring captured between the cartridge base and
flipper arm in tension to facilitate return of the flipper arm to
the molding or operating position after being pivoted during part
removal or demolding away from the molding or operating position
and toward a molded component release position.
[0020] The flipper assembly is configured so the flipper arm is
pivotably mounted by a pivot that enables pivoting of the flipper
arm during molding and demolding between the molding and molded
component release positions with the flipper arm having a center of
gravity located forwardly relative to the pivot to facilitate
return of the flipper arm to the molding or operating position by
gravity acting on the flipper arm producing supplemental return
force that assists the return force of the return spring.
[0021] Various other features, advantages, and objects of the
present invention will be made apparent from the following detailed
description and any appended drawings.
DRAWING DESCRIPTION
[0022] One or more preferred exemplary embodiments of the invention
are illustrated in the accompanying drawings in which like
reference numerals represent like parts throughout and in
which:
[0023] FIG. 1 is a top front perspective view of a preferred
embodiment of a pivotable flipper assembly constructed in
accordance with the present invention;
[0024] FIG. 2 is a cross sectional view of the pivotable flipper
assembly of FIG. 1 taken through line 2-2 where a flipper arm is in
a first position;
[0025] FIG. 3 is a side elevation view of the pivotable flipper
assembly of FIGS. 1 and 2 where the flipper arm is pivoted to a
second position;
[0026] FIG. 4 is an exploded top front perspective view of the
pivotable flipper assembly of FIGS. 1-3;
[0027] FIG. 5 is a top plan view of another embodiment of the
pivotable flipper assembly;
[0028] FIG. 6 is a bottom perspective view of a base associated
with a preferred embodiment of the pivotable flipper assembly
depicted in FIGS. 1-5;
[0029] FIG. 7 is a side elevation view of the pivotable flipper
assembly of FIG. 5;
[0030] FIG. 8 is a top plan view of another embodiment of the
pivotable flipper assembly illustrating another embodiment of a
flipper arm having a different size or shape;
[0031] FIG. 9 is a side elevation view of the pivotable flipper
assembly of FIG. 8;
[0032] FIG. 10 is a top plan view of yet another embodiment of the
pivotable flipper assembly illustrating a further preferred
embodiment of a flipper arm having yet another three-dimensional
contour, shape and/or size;
[0033] FIG. 11 is a side elevation view of the pivotable flipper
assembly of FIG. 10;
[0034] FIG. 12 is a top plan view of a further embodiment of the
pivotable flipper assembly;
[0035] FIG. 13 is a perspective view of a mold having a plurality
of pivotable flipper assemblies mounted therein;
[0036] FIG. 14 is a top front perspective view of a package formed
using a mold and flipper assemblies of FIG. 13; and
[0037] FIG. 15 is a top front perspective view of the package of
FIG. 14 releasably holding a beam-blade type windshield wiper
blade.
[0038] Before explaining one or more embodiments of the invention
in detail, it is to be understood that the invention is not limited
in its application to the details of construction and the
arrangement of the components set forth in the following
description or illustrated in any appended drawings. The invention
is capable of other embodiments, which can be practiced or carried
out in various ways. Also, it is to be understood that the
phraseology and terminology employed herein is for the purpose of
description and should not be regarded as limiting.
DETAILED DESCRIPTION
[0039] The present invention is based on the inventors' discovery
that prior art undercut forming mechanisms in the form of flipper
assemblies not only suffered from overstretching of the return
spring leading to premature spring failure and increased part
defect rates, but that overstretching of the spring occurred due to
non-linear stretching or non-linear deformation of the spring
during each thermoforming molding cycle. It was further discovered
the cause of the non-linear stretching or non-linear deformation of
the return spring was due to part of the spring contacting the
pivot pin about which the flipper rotates during thermoformed part
removal. As the flipper pivoted about its pivot pin during part
removal, the portion of the return spring disposed between the
pivot pin and the flipper would stretch or deform excessively
thereby plasticly deforming and overstretching that portion
reducing the return force the overstretched spring could generate.
When too much plastic deformation or overstretching occurred and
the return spring force became too low, the flipper would fail to
return to its home or molding position thereby producing
defectively thermoformed parts until the overstretched return
spring was replaced. As depicted in the drawing figures and
disclosed in more detail below, a flipper assembly constructed in
accordance with the present invention is configured such that the
return spring does not contact any part of the pivot pin nor any
other part of the flipper assembly during pivoting of the flipper
between the home or molding position and a molded part release
facilitating position, demolding or part removal position thereby
preventing nonlinear elongation and overstretching of the
spring.
[0040] The present invention is based on the inventors' further
discovery that some flipper assembly orientations and flipper
configurations resulted in the force of gravity acting on the
flipper in a way that opposed or counteracted the return force of
the spring enough to prevent the flipper from reliably and
repeatably returning to the home or molding position even when the
spring was not overstretched enough to require replacement. As
further depicted in the drawing figures and disclosed below, a
flipper assembly constructed in accordance with this further aspect
of the invention is configured so the force of gravity acting on
the flipper works in concert with the force of the return spring,
including by acting in a similar or same direction as the return
spring force, produces a flipper assembly of the invention that
more reliably and repeatably travels between the molding and
demolding positions, possesses increased return spring life, and
which reliably operates in orientations not previously heretofore
believed usable.
[0041] A flipper assembly constructed in accordance with the
present invention advantageously operates more reliably for a
longer time, is more versatile, enables deeper, larger and more
aggressive undercuts and fingers to be thermoformed, and can be
used in orientations and applications where other types of undercut
thermoforming devices are not well suited.
[0042] With reference to FIGS. 1-15, the present invention is
directed to a flipper assembly 50 for use in a mold 52 of a molding
or forming machine 51, such as depicted in FIG. 13, in carrying out
a molding or forming process to mold or form a relatively long
projection, preferably an elongate or extreme undercut, more
preferably a flipper or finger, in a molded or formed component 54
that preferably is a reclosable article-holding package 55, which
more preferably is a reclosable wiper blade package 61, such as
depicted in FIGS. 14 and 15, during molding or forming of the
component 54. With reference to FIG. 13, a plurality of the flipper
assemblies 50 of the present invention are removably installed
adjacent one another side-by-side in a thermoforming mold 52 of a
thermoforming machine 57, e.g., vacuum thermoforming machine, with
each flipper assembly 50 configured with a pivotable flipper arm 64
having an outwardly extending three-dimensionally contoured
undercut forming surface 65 that projects outwardly into a
three-dimensionally contoured cavity 53 of the mold 52 during
thermoforming of the molded component 54.
[0043] With continued reference to FIGS. 13-15, the undercut
forming surface 65 of the flipper arm 64 extends into the mold
cavity 53 in the mold 52 and is configured to three-dimensionally
thermoform an elongate outwardly projecting undercut 59, preferably
in the form of a finger 58, e.g., an elongate article-retaining
finger, which projects into an article-holding compartment 60 of
the thermoformed molded component 54. FIG. 14 illustrates a
three-dimensionally contoured thermoformed molded component 54 that
is a portion of a three-dimensionally contoured thermoformed
reclosable package 55 that preferably is a three-dimensionally
contoured thermoformed wiper blade package 61 after being
thermoformed in thermoforming mold 52 and using the plurality of
flipper assemblies 50 to respectively thermoform a plurality of
side-by-side article-retaining fingers 58 that both project into
the article-holding compartment 60 in the package 61 and are
configured to releasably retain an article 135 (FIG. 15) therein.
FIG. 15 illustrates the molded component 54 of FIG. 14 with an
article 135 releasably retained in a three-dimensionally contoured
article-holding compartment 60 thermoformed therein that is a wiper
blade 138, preferably a pre-curved or pre-tensioned beam-type wiper
blade or beam blade, which each one of the thermoformed fingers 58
engaged with an elongate beam 137 of the blade 138 to help
releasably hold the blade 138 in the package 61 in the compartment
60 with the beam 137 and blade 138 releasably retained by the
fingers 58 in at least a partially straightened condition. In the
preferred thermoformed reclosable beam-blade wiper blade package 61
depicted in FIG. 15 with article-engaging fingers 58 thermoformed
with flipper assemblies 50 of the present invention is configured
to engage and releasably retain an elongate beam 137 of a beam-type
wiper blade 138 in a substantially straightened condition with the
beam 137 held substantially straight in the compartment 59 of the
package 61. Such a flipper assembly 50 of the present invention is
therefore particularly well suited for use in thermoforming
reclosable wiper blade packaging, including the wiper blade
packages disclosed in commonly owned U.S. Pat. Nos. 10,035,642;
9,567,152; 9,139,347; 8,910,789; 8,613,357; and 8,042,690, the
entirety of each of which is hereby expressly incorporated herein
by reference.
[0044] As known to those of ordinary skill in the art, the
thermoforming process consists of heating a sheet of material, such
as plastic, e.g., polyethylene terap or other resinous material, to
a desired temperature before contacting the heated sheet with the
mold. For instance, oftentimes a vacuum is applied to the heated
sheet to suck the sheet against the mold. Thereafter, material is
cooled, and the sheet substantially retains the shape of the mold.
During thermoforming of molded component 54, the pivotable flipper
arm 64 of a flipper assembly 50 of the present invention is
configured to pivots relative to the mold 52 between a molding or
thermoforming position, shown in FIG. 2, where the flipper arm 64
is disposed in the mold cavity 53 during thermoforming, and a
molded component release facilitating position, e.g., demolding
position, such as depicted FIG. 3, where the flipper arm 64 is
pivotably disposed outwardly away from the mold cavity 53 during
demolding or removal of the finished molded component 54 from the
mold 52.
[0045] With reference once again to FIGS. 1-7, a flipper assembly
50 constructed in accordance with the present invention is
specifically configured to allow for thermoformed components 54,
such as reclosable wiper blade packages 61, which have extreme
undercuts 56 and/or fingers 58 thermoformed therein that extend
into an article holding cavity 60 of the thermoformed component 54,
e.g., wiper blade package 61, being thermoformed. While these
extreme undercuts 56 and/or fingers 58, can be configured to
improve the durability and strength of thermoformed components 54,
particularly wiper blade packages 61, which are relatively
thin-walled, it can be difficult to remove each component 54, e.g.,
package 61, from the mold 52 once the thermoforming process has
been completed and the component 54 has been cooled without
damaging or even destroying the component 54. A flipper assembly 50
constructed in accordance with the present invention is
specifically configured to allow the thermoformed component 54,
e.g., package 61, to be removed from the mold 52 once thermoforming
is done, while minimizing the risk that the component 54 is damaged
by the mold 52 and/or the flipper assembly 50.
[0046] The flipper assembly 50 includes a mounting base 62
removably fixed to part of the mold 52, a flipper arm 64
operatively connected to the base 62 and configured to move
relative to the base 62 and the mold 52 during thermoforming
machine operation, and a pivot 75 operatively connecting the
flipper arm 64 to the base 62 and configured to enable the flipper
arm 64 to move relative to the base 62 and mold 52 by pivoting or
rotating about the pivot 75. The flipper arm 64 is pivotably
connected to the base 62 by the pivot 75 and configured to pivot
relative to the base 62 and mold 52 during thermoforming machine
operation between a first or molding position, such as shown in
FIG. 2, where the outwardly projecting undercut forming surface 65
forms an undercut or preferably a finger in the thermoformed part
54, e.g. wiper blade package 61, and a second or demolding
position, such as depicted in FIG. 3, during removal of the same
part 54, e.g., package 61, from the mold 52.
[0047] The base 62 is configured for removable mounting to part of
the mold 52 and configured for removable attachment of one of a
plurality of differently shaped or sized flipper arms 64 having one
of a plurality of different lengths, widths, thicknesses, or outer
undercut forming surfaces 65. With reference to FIG. 6, the base 62
has a bottom 104 with a plurality of threaded mounting openings
108, 110 formed therein for removable mounting to the mold 52 using
threaded fasteners (not shown), such as a plurality of threaded
bolts (not shown). The base 62, flipper arm 64, and rest of the
components that form a flipper assembly 50 constructed in
accordance with the present invention produce a "plug and play"
modular flipper cartridge 73 or flipper assembly cartridge module
77 that can be just as easily be attached to a mold 52 as be
removed from the mold 52.
[0048] As previously indicated, during thermoforming machine
operation, the flipper arm 64 rotates relative to base 62 and mold
52 by rotating about the pivot 75 between the first or molding
position, shown in FIG. 2, and a second, part removal or demolding
position, such as depicted in FIG. 3, where the flipper arm 64 is
disposed in a rotational position distal from the first or molding
position. In the flipper assembly 50 shown in FIGS. 2 and 3, the
flipper arm 64 is rotated upwardly counterclockwise from the
generally horizontal first or molding position towards a second,
part removal, or molded component demolding position by the
thermoformed component 54, preferably wiper blade package 61, being
pulled free of the mold 52 during demolding. As is shown in FIGS. 2
and 3, when disposed in the second, part removal or demolding
position, the flipper arm 64 is oriented at an oblique angle and
can be oriented at a right angle from or relative to the flipper
arm 64, when disposed in the first or part molding position.
[0049] The base 62 of the flipper assembly 50 shown in FIGS. 1-7 is
generally vertically oriented when mounted in the mold 52 and
preferably larger than the flipper arm 64. The flipper arm 64 is
generally horizontally oriented when disposed in the first or
molding position, and the flipper arm 64 is disposed at an angle
relative to horizontal when disposed in a second, molded component
removal, or part demolding position. The flipper arm 64 is elongate
and has a flipper arm body 122 from which a narrowed or necked down
outwardly projecting three-dimensionally contoured undercut or
finger forming tongue 134 outwardly extends which has an arcuate or
rounded nose 125 at its free end collectively defining a
three-dimensionally contoured undercut forming outer surface 65
around which the undercut or finger of the component 54, preferably
wiper blade package 61, is formed during thermoforming of the
component 54, preferably package 61, in the mold 52. The flipper
arm 64 is configured with a center of gravity, Cg, disposed
outwardly of the pivot 75 such that the force of gravity acting on
the weight or mass of the flipper arm 64 generates, produces or
provides a flipper arm return force, RF1, in a direction opposing
rotation of the flipper arm 64 away from the first or molding
position shown in FIG. 2. When the flipper arm 64 is disposed in
its generally horizontal molding position, such as the molding
position shown in FIG. 2, the force of gravity acting on the center
of gravity, Cg, of the flipper arm 64 generates, produces or
provides a generally downwardly acting gravity-actuated flipper arm
return force, RF1, such as also shown in FIG. 2, which holds or
helps hold the flipper arm 64 in the molding position during
thermoforming of a molded component 54, preferably package 61, in
the mold 52. When the molded component 54, e.g., package 61, is
released and being pulled out of the mold 52 during demolding,
separation of the molded component 54, e.g., package 61, from the
mold 52 rotates the flipper arm 64 away from the molding position
towards a part demolding position, such as depicted in FIG. 3,
disposed distal to or away from the molding position. When the
molded component 54, e.g., package 61, completely disengages or
separates from the flipper arm 64, the force of gravity acting on
the center of gravity, Cg, of the flipper arm 64 generates,
produces or provides a generally downwardly acting gravity-actuated
flipper arm return force, RF1, that returns or helps return the
flipper arm 64 from a demolding position, e.g., the generally
vertical demolding position depicted in FIG. 3, back to the
generally horizontal molding position shown in FIG. 2. When the
flipper arm 64 is disposed in the molding position, the undercut or
finger forming surface 65, including elongate nose 134, extends or
projects outwardly from the base 62 into the cavity 53 of the
thermoforming mold 52 ready for thermoforming another component 54,
preferably wiper blade package 61.
[0050] While a flipper assembly 50 constructed in accordance with
the present invention can be composed of the base 62, flipper arm
64, and a pivot 75 formed of an elongate generally cylindrical
pivot pin 78 received in flipper arm pivot pin receiving bores 80
and 82 formed respectively in the base 62 and flipper arm 64, the
flipper arm 64 can be operatively connected to the base 50 by a
flipper arm return biasing element 85, such as a spring 66, which
is configured to provide a biasing element-actuated flipper arm
return force, RF2, that preferably is a spring-actuated flipper arm
return force, RF2, in lieu of or in addition to gravity-actuated
the return force, RF1, provided by gravity acting on the flipper
arm center of gravity, Cg.
[0051] Where a spring 66 is used to provide biasing element flipper
arm return force, RF2, the spring 66 preferably disposed in
operable cooperation with both the flipper arm 64 and base 62 and
configured to impart or exert a spring-actuated return force, RF2,
on the flipper arm 64 that causes the flipper arm 64 to pivot or
rotate about pivot 75 from a demolding position towards its molding
position. With reference to FIGS. 2 and 4, a preferred flipper
assembly 50 constructed in accordance with the present invention
employs an elongate, generally cylindrical coil spring 67 having
one end operatively connected by a first spring anchor pin 76 to
the base 62 and the other end operatively connected a second spring
anchor pin 78 to the flipper arm 64 with the coil spring 67
captured in tension therebetween. The spring 67 is housed within
the flipper assembly 50 having one section of the spring 67
extending from the end attached to spring anchor pin 76 received in
an elongate generally cylindrical first spring conduit 87 formed in
the base 62 and another section of the spring 67 extending from the
end attached to spring anchor pin 78 received in a second spring
conduit 89 that preferably is a generally U-shaped channel 91
formed in between a pair of parallel spaced apart elongate lobes 93
of the flipper arm 64 (only one lobe 93 of which is shown). As the
flipper arm 64 is rotated relative to the base 62 and mold 52 away
from the molding position towards a demolding position disposed
from the molding position, stretching of the coil spring 67
generates a spring-actuated flipper arm return force, RF2, on the
flipper arm 64 that opposes additional rotation away from the
molding position. When the molded component 54, e.g., wiper blade
package 61, separates or disengages from the flipper arm 64 during
demolding, the spring-actuated element return force, RF2, urges the
flipper arm 64 to rotate back to the molding position to ready the
flipper arm 64 for another thermoforming cycle.
[0052] Where the molding position of the flipper arm 64 is
generally horizontal and a return force, RF2, provided by a biasing
element 85, such as spring 66, a flipper assembly 50 of the present
invention is a gravity assisted spring actuated flipper assembly 50
because gravity-actuated flipper arm return force, RF1, provided by
gravity acting on the center of gravity, Cg, of the flipper arm 64
assists the biasing element actuated flipper arm return force, RF2,
provided by biasing element 85, preferably spring 66, more
preferably coil spring 67, in rotating or pivoting the flipper arm
64 away from a demolding position back towards the molding position
thereby readying the flipper arm 64 and mold 52 to thermoform
another component 54, preferably wiper blade package 61. Where the
flipper assembly 50 is of gravity return assisted construction, the
center of gravity, Cg, of the flipper arm 64 preferably is disposed
in a longitudinal or lengthwise direction of the flipper arm 64
forwardly of both the pivot 75, e.g., pivot pin 74, and the flipper
arm spring anchor pin 78, when the flipper arm 64 is disposed in a
molding position that is generally horizontal, like the generally
horizontal molding position shown in FIG. 2. Where the molding
position of the flipper arm 64 is a generally horizontal molding
position, such as depicted in FIG. 2, the center of gravity, Cg, of
the flipper arm preferably is disposed in a height-wise direction
of the flipper arm 64 between the pivot 75, e.g., pivot pin 74, and
the flipper arm spring anchor pin 78. The center of gravity, Cg,
preferably is generally centrally located in a widthwise direction
relative to the flipper arm, such as is depicted in FIG. 1.
[0053] As previously discussed, the flipper assembly 50 preferably
is a spring-actuated and gravity assisted flipper assembly 50 but
can be configured or implemented using only gravity as the actuator
that provides the flipper arm return force, e.g., RF1. Where
actuated only using gravity, flipper assembly 50 would be
constructed or configured without any biasing element 85, spring
66, coil spring 67, or spring anchor pins 76, 78, relying only on
gravity acting on the mass of the flipper arm 64, more specifically
acting on the center of gravity, Cg, of the flipper arm to
generator, produce or provide gravity-actuated flipper arm return
force, RF1, that pivots the flipper arm 64 back to the molding
position after demolding is completed.
[0054] However, the flipper arm 64 of flipper assembly 50 may be
actuated using a variety of different actuators, such as
gravity-actuated, magnetic field actuated, by use of a biasing
element actuator that is an elastomeric actuator, a spring actuator
that is a torsion spring, or by use of another type of actuator
configured to operably cooperate with the base 62 and flipper arm
64 to provide a flipper arm return force that rotates or pivots the
flipper arm 64 from a demolding position back to the molding
position. If desired, the flipper arm 64 of a flipper assembly 50
constructed in accordance with the present invention may be
actuated using a plurality of actuators each contributing or
providing a flipper arm return force with combinations contemplated
as being within the scope of the present invention including
gravity actuated and biasing element actuated, gravity actuated and
spring actuated, and/or gravity actuated and magnet actuated with
gravity being an actuator acting on the center of gravity, Cg, of
the flipper arm to provide gravity actuated flipper arm return
force, RF1, as discussed above. As previously discussed, a
preferred embodiment of a flipper assembly 50 constructed in
accordance with the present invention is a biasing element
actuated, preferably spring actuated, and gravity assisted flipper
assembly 50 of the invention that employs gravity as a flipper arm
return assisting actuator that acts on the center of gravity, Cg,
of the flipper arm to generate a gravity-actuated or
gravity-assisted flipper arm return force, RF1, that assists the
biasing element, preferably spring actuated, flipper arm return
force, RF2, provided by biasing element 85, preferably spring 66,
more preferably coil spring 67, in returning flipper arm 64 to the
generally horizontal molding position shown in FIG. 2.
[0055] With continued reference to FIGS. 1-7, the flipper assembly
50 includes a base 62, a flipper arm 64, and a resilient
mechanically operable flipper arm biasing arrangement 65
operatively connected to the flipper arm 64 and base 62 that
preferably is or includes a spring 66. During operation, the
flipper arm 64 is movable relative to the base 62 and the mold in
which the base 62 is fixed between a first position that is a
thermoformed part molding position, like that depicted in FIG. 2,
and a second position that is a second position that is a part
demolding position, like that depicted in FIG. 3, which is disposed
away from the first or molding position.
[0056] The flipper arm biasing arrangement 65 is disposed in
operable cooperation with the flipper arm 64 and base 62 preferably
operatively cooperating with the flipper arm 64 and base 62 to
oppose rotation or oppose movement of the flipper arm 64 away from
the molding position when being displaced towards a demolding
position disposed from the molding position during removal of the
thermoformed part, e.g., thermoformed component 54, from the mold
of the thermoforming machine. In a preferred embodiment, the
flipper arm biasing element arrangement 65 is a spring 66,
preferably coil spring 67, which operatively extends between the
flipper arm 64 and the base 62, preferably operatively connecting
the flipper arm 64 and base 62, and more preferably extending
between or linking the flipper arm 64 and base 62. As previously
discussed, the biasing element arrangement 85 is a lone biasing
element captured in tension whose stretching during rotation of the
flipper arm 64 away from the molding position, such as the molding
position shown in FIG. 2, and towards a demolding position, such as
the demolding position shown in FIG. 3, generates a flipper arm
return force, RF2, that opposes rotation towards the demolding
position and urges the flipper arm 64 towards the molding
position.
[0057] For instance, as shown in FIGS. 2, 7, 9, and 11 the flipper
arm 64 is in a first position 68. The first position 68, e.g.,
forming or molding position, is where the flipper arm 64 naturally
rests prior to and during the thermoforming process. In the first
position 68, the flipper arm 64 extends substantially perpendicular
relative to the lengthwise direction or height 72, e.g.,
height-wise direction, of the base 62. The flipper arm 64 is shown
in the second position 70, e.g., a molded component demolding
facilitating position, in FIG. 3 where the flipper arm 64 extends
substantially parallel to the lengthwise direction or height 72,
e.g., height-wise direction, of the base 62. The flipper arm 64
moves from the first position 68 to the second position 70 while
the thermoformed component 54 is being removed from the mold 52.
Once the flipper arm 64 has been moved to the second position 70
and the thermoformed component 54 has been disengaged from the
flipper arm 64, the spring 66 causes the flipper arm 64 to
automatically be returned to the first position 68, e.g.,
thermoforming position.
[0058] Additionally, the center of gravity Cg of the flipper arm 64
minimizes vector forces required to return the flipper arm 64 to
the first position, which in turn allows the flipper arm 64 to more
easily return to this position with minimal force by the spring 66.
More specifically, the location of a pivot pin 74 of the flipper
arm 64, which will be further described below, is located about the
flipper arm 64 at a location that results in a center of gravity Cg
that is configured to minimize the magnitude of force that is
required to return the flipper arm 64 from the second position 70
to the first position 68. Stated differently, the center of gravity
Cg may further be located to minimize the vector force required to
return the flipper arm 62 to the first position 68. As shown in
FIGS. 1, 2, and 4, the center of gravity Cg is located in close
proximity to the pivot pin 74 of the flipper arm 64. Placement of
the pivot pin 74 and the center of gravity Cg of the flipper arm 64
may be optimized based on the position and orientation of the
flipper arm 64 relative to the base 62. Further still, the position
and orientation of the flipper arm 64 and/or the base 62 may be
selected to utilize gravitational forces to further help return the
flipper arm 64 to the first position 68. The center of gravity Cg
and the spring 66 are force vectors that impact movement of the
flipper arm 64, and more specifically movement of the flipper arm
64 from the second position 70 to the first position 68. The spring
66 will always serve as a return force vector. In contrast, the
center of gravity Cg may be a return force vector, or it can be a
force vector that opposes the return of the flipper arm depending
on its location and orientation.
[0059] The spring 66 also retains the flipper arm 64 in the first
position 68, e.g., the thermoforming position, during thermoforming
of the component 54 in the three-dimensionally recessed mold cavity
of the mold 52. The flipper assembly 50 of the present invention is
configured with a spring 66 in tension that movably, e.g.,
rotatively, operatively connects or operably couples the flipper
arm 64 to the base 62 having a spring constant sufficient to permit
the flipper arm 64 to move, preferably rotate, relative to the base
62 between the first position, the thermoforming position, during
component molding, and the second position, the demolding
facilitating position, during molded component removal. The flipper
assembly 50 is configured with a spring 66 having a sufficient
spring constant, spring tension, or spring force to resiliently
retain the flipper arm 64 in the first position, the thermoforming
position, and also resiliently urge the flipper arm 64 back towards
the first position, the thermoforming position, after the flipper
arm 64 is displaced by component 54 during removal of the formed or
finished thermoformed component 54 from the cavity of the mold 52.
The flipper assembly 50 also is configured with the spring 66
having a sufficient spring constant, spring tension, or spring
force to allow a portion of the finished thermoformed component 54
in contact with part of the flipper arm 64 to displace the flipper
arm 64, preferably by rotating the flipper arm 64 relative to the
base 62 and mold 52 toward the second position, the demolding
position, by separation of the finished thermoformed component 54
away from the mold 52 during demolding of the component 54 after
thermoforming of the component 54 is finished. The flipper assembly
50 is further configured with the spring 66 having a sufficient
spring constant, spring tension or spring force to return the
flipper arm 64 back to the first position, the thermoforming
position, when the portion of the component 54 in contact with the
flipper arm 64 disengages or separates from the flipper arm 64
during demolding of the finished package 54. As shown, the flipper
assembly 50 is preferably configured such that the spring 66
extends in a linear fashion only while the flipper arm 64 is moved
between the first and second positions. In doing so, the spring 66
can functionally operate for a much longer period of time prior to
failure in comparison to springs that are extended in non-linear
fashion.
[0060] The flipper assembly 50 can and preferably does include a
plurality of pins that helps to enable the use of the flipper
assembly 50 and to secure the spring 66 in place relative to the
base 62 and the flipper arm 64. To enable the flipper arm 64 to be
moved away from the first position toward the second position by a
portion of the molded component, preferably thermoformed component
54, during separation of the molded component, preferably packaging
54, from the mold 52 during demolding, the flipper arm 64 is
attached to the base 62 by a pivot that preferably is an elongate
pivot pin 74 that extends through at least part of the flipper arm
64 into a portion of the base 62 disposed along one side and
preferably disposed along both sides of the flipper arm 64. For
instance, the illustrated embodiment includes a first pin 74 that
provides a flipper arm pivot enabling pivoting of the flipper arm
64 relative to the base 62 and mold 52 between the first and second
positions during cycling of the thermoforming mold. The first pin
74 is a flipper arm pivot that extends through openings 80 formed
in base 62, as well as openings 82 formed in the flipper arm 64.
The flipper arm 64 is pivotable relative to the base 62 about the
first pin 74, such that the flipper arm 64 pivots from the first
position 68 to the second position 70 relative to the first pin
74.
[0061] The illustrated embodiment may also include a second pin 76,
and a third pin 78. The second pin 76 can and preferably does
extend through an opening 84 formed in a lower portion 86 of the
base 62. The second pin 76 preferably is a first spring anchor that
is configured to also extend through a first end 88 of the spring
66 thereby anchoring the first end 88 of the spring 66 to the base
62. The first end 88 is shown in FIGS. 2 and 4. Because the second
pin 76 is not moveable relative to the base 62, the first end 88 of
the spring 66 also remains in place such that the second pin 76
anchors the spring 66 to the base 62.
[0062] Similarly, the third pin 78 extends through an opening 90
formed in the flipper arm 64, as well as a second end 92 of the
spring 66 and functions as a second spring anchor that anchors the
opposite end or second end 92 of the spring 66 to the flipper arm
64. As can be seen in FIG. 2 the first pin 74 is vertically offset
from the second pin 76. This offset of the first pin 74 and the
second pin 76 causes the spring 66 to extend and retract primarily,
and more preferably only in a linear direction. Since the flipper
arm 64 is pivotable relative to the base 62, the second end 92 of
the spring 66 is also movable relative to the base 62. Because the
first end 88 of the spring 66 is secured to the base 62 relative to
the second pin 76, and the second end 92 of the spring 66 is
secured to the flipper arm 64 relative to the third pin 78, but is
pivotable relative to the base 62, the spring 66 is extended from a
resting position as the flipper arm 64 is rotated from the first
position 68 to the second position 70 to an extended position.
Again, this movement is preferably linear to minimize damage to the
spring 66. While the spring 66 allows this movement to occur, it
will automatically bias back toward the resting position where the
spring 66 is less extended. This is especially true given that the
center of gravity of the flipper arm 64 allows the flipper arm 64
to be returned to the first position with minimal force. When the
flipper arm 64 is released, the spring 66 automatically retracts,
preferably in a linear fashion, which causes the flipper arm 64 to
rotate back from the second position 70 to the first position 68.
In this way, the flipper arm 64 only rotates to the second position
70 when the thermoformed component 54 is removed from the flipper
assembly 50. As the thermoformed component 54 is disengaged first
from the mold 52 and then from the flipper arm 64 during demolding,
the flipper arm 64 automatically moves back to the first position
due to the strength of the spring 66, as well as its connection to
the second pin 76 and third pin 78, and base 62 and flipper arm 64
by extension.
[0063] As best shown in FIGS. 1-4, the flipper arm pivot is an
elongate pivot pin 74 that extends completely through a
longitudinal extent of the flipper arm 64 and into at least a
portion of the base 62 disposed along either side or end of the
flipper arm 64 defining a longitudinal pivot axis about which the
flipper arm 64 pivots. The pivot, preferably pivot pin 74,
preferably is offset to one side of a longitudinal center or
longitudinal centerline of the flipper arm 64 so that the pivot,
preferably pivot pin 74, defines a moment arm about which the
flipper arm 64 pivots during mold cycling or thermoforming cycling.
By offsetting the pivot, preferably pivot pin 74, relative to a
longitudinal center or longitudinal centerline of the flipper arm
64, gravity can act as a downward force on a portion of the flipper
arm 64 opposite the pivot, preferably pivot pin 74, producing a
moment about the pivot, preferably pivot pin 74, which can act in
concert with the spring 66 and help return the flipper arm 64 from
the second or demolding position to the first or thermoforming
position.
[0064] The flipper arm 64 is disposed in a recessed flipper arm
seat 107 formed in a top portion of the base 62 in which the
flipper arm 64 is received or seats when the flipper arm 64 is
disposed in the first or thermoforming position. When received in
the flipper arm seat 107, the flipper arm 64 is surrounded on three
sides by an upraised portion of the base 62 that forms or defines
the top of the base 62.
[0065] When seated in the flipper arm seat 107, the flipper arm 64
is bounded along one longitudinal side of the flipper arm 64 by an
upraised elongate rear portion of the top of the base 62 and is
bracketed along each end of the flipper arm 64 by respective
upraised sides of the top of the base 62. The flipper arm pivot
preferably is an elongate pivot pin 74 that extends through the
entire longitudinal extent of the flipper arm 64 into both upraised
sides of the top of the base 62. The pivot, preferably elongate
longitudinally extending pivot pin 74, is offset towards the rear
portion of the top of the base 62 such that the pivot pin 74 is
disposed between the rear portion of the top of the base 62 and the
spring 66.
[0066] The result of positioning the pivot, preferably pivot pin
74, between the rear portion of the top of the base 62 and spring
66 is that a spring flipper arm return force is produced that is a
moment about the pivot, preferably pivot pin 74, which more readily
and efficiently urges the flipper arm 64 to return to the first or
thermoforming position where the flipper arm 64 is received in the
recessed flipper arm seat formed in the top of the base 62 after
being pivoted away from the first or thermoforming position during
molded component, preferably thermoformed component 54, demolding.
In doing so, the pivot, preferably pivot pin 74, forms a moment arm
about which the flipper arm 64 pivots between the first or
thermoforming position and the second or demolding position. In
doing so, the pivot, preferably pivot pin 74, forms a moment arm
about which the flipper arm 64 pivots between the first or
thermoforming position and the second or demolding position.
[0067] Selective embodiments of the flipper arm 64 and base 62 will
now be described. While the figures show various embodiments of the
flipper arm and base, it should be known that the specific
dimensions and shapes of the flipper arm and base can be varied
depending on the desired dimension and shape of the undercut,
finger, flipper, notch, or the like in the final thermoformed
component. As will be appreciated looking to the resulting
thermoformed component shown in FIGS. 14 and 15, the ultimate shape
of the undercut, finger, flipper, notch, or the like will directly
correlate to the cross-sectional view of the base and flipper
arm.
[0068] Looking to the figures generally, the base 62 has a front
wall 94, a rear wall 96, first and second sidewalls 98, 100, a top
side 102, and a bottom side 104. Additionally, a middle side
platform 106 can be offset from the top side 102 to form a seat
107. The flipper arm 64 can rest on top of the middle side platform
106 and can be rotated relative to the base 62 upwardly to the
second position 70, as described above. The rear wall 96, first and
second sidewalls 98, 100, and bottom side 104 are all substantially
flat, which allows the base 62 to be secured into the mold 52.
Additionally, a plurality of openings can be formed in the bottom
side 104, as can be seen in FIG. 6. For instance, first and second
threaded openings 108, 110 can be found in opposite ends of the
bottom side 104 of the base 62. Various bolts, screws, and the like
(not shown) can be used to secure the base 62 to the mold 52.
Additionally, an open shaft 112 can be formed from the bottom side
104 up through the middle side platform 106. This allows the spring
66 to be mounted within the open shaft 112, with the first end 88
being secured in place by the second pin 76, and the second end 92
being secured in place by the third pin 78.
[0069] The front wall 94 can have a number of ridges formed
therein. For instance, looking to FIGS. 5 and 6, the front wall 94
has a first ridge 114 and a second ridge 116. Of course, the front
wall 94 could similarly have additional or fewer ridges, as
desired. Again, when the thermoformed component 54 is formed, a
heated sheet of plastic is vacuumed against the flipper assembly
50, including the first ridge 114 and the second ridge 116.
Therefore, the resulting thermoformed component 54 has notches 118
formed therein that are complimentary in size and shape as the
ridges 114, 116. Any of these ridges could have different sizes,
curvatures, and shapes based on the desired sizes and shapes of the
notches in the thermoformed component. FIGS. 9 and 11 show a
slightly different embodiment in which the front wall 94 only has a
single ridge 114. Thus, the resulting thermoformed component only
has a single notch 118. Additionally, FIGS. 1-4 includes a single
ridge 117 that may extend partially across the front wall 94. This
ridge 117 may have a curved inner face 119 that slopes downwardly
towards the bottom side 104. Further still, the various flipper
assemblies mounted to the mold 52 in FIG. 14 have front walls 94
that are substantially straight. Additionally, the front wall 94
could be sloped and it could include various textured features, as
desired.
[0070] Next, the flipper arm 64 will be further described. The
flipper arm 64 includes a base 122 having a top side 124, an
underside 126, first and second sidewalls 128, 130, and a backwall
132. The flipper arm 64 also has a tongue 134 with an arcuate nose
135 extending from the front of the base 122. As shown, the tongue
134 tapers downwardly from the top side 124, upwardly from the
underside 126, and inwardly from the first sidewall 128 and the
second sidewall 130. As seen in the embodiment in FIGS. 1-5, the
tongue 134 can be substantially elongate in shape. Alternatively,
as seen in FIGS. 8 and 10, the tongue 134 can be narrower in shape.
Further still, as shown in FIG. 6, the tongue 134 can be
substantially pointed in shape. Of course, the specific shape of
the flipper arm 64 is dependent on the desired shape of the notch
that will be formed in the thermoformed component during the
thermoforming procedure.
[0071] Also, the flipper arm 64 can include a channel 91 formed in
the underside 126. As shown, the channel 91 extends from the back
wall 132 towards the tongue 134. The channel 91 is located to
facilitate the spring 66. As such, the openings 82 extending from
the first sidewall 128 to the second sidewall 130 intersects with
the channel 91. When the third pin 78 is inserted into the opening
82 at the first sidewall 128, it is then threaded through the
second end 92 of the spring 66 and through the opening 82 at the
second sidewall 130.
[0072] Additionally, a method of thermoforming a sheet into a
thermoformed component is provided. This can include initially
placing a sheet of material into a mold having a flipper assembly
as described above. The sheet of material can be heated to a
pliable temperature. Thereafter, a pressure differential can be
applied to create a suction of the sheet against the flipper
assembly. This causes a three-dimensionally contoured component to
be formed against the front wall and the flipper arm with a finger,
undercut, and/or notch that is formed when the sheet is pressed
against a front edge of the flipper arm. Next, the flipper arm can
be rotated from the retracted position to the deployed position to
release the thermoformed component from the flipper assembly
without distorting the thermoformed component. Thereafter, the
flipper arm is rotated to the retracted position by the spring. The
cross-sectional profile of the thermoformed component can be
substantially the same shape as the cross-sectional profile of the
base and flipper arm.
[0073] Additionally, a method of assembling the flipper assembly 50
is provided. First, the spring 66 may be inserted through the shaft
112 of the cartridge 62. Next, the pin 76 is inserted through the
opening 84 of the base and through the first end 88 of the spring
66. Next, pin 74 is inserted through the opening 80 of the
cartridge and into the opening 82 of the flipper arm 64.
Thereafter, the spring 66 is stretched to the flipper arm 64 and
the spring pin 78 is inserted through the flipper arm 64 and the
second end 92 of the spring 66.
[0074] As shown, the thermoformed component 54 shown in FIGS. 14
and 15 is configured to hold a wiper blade 138. Due to the specific
shape of the thermoformed component 54, the wiper blade 138 is held
in a substantially straightened condition to minimize the
thermoformed component volume and to maximize retail display
package density. However, the flipper assembly 50 could be used to
create packages configured to hold any number of different
items.
[0075] A flipper assembly 50 constructed in accordance with the
present invention is configured to form or mold a
three-dimensionally contoured feature, such as an outwardly
protruding undercut or finger, in or into a component, e.g.,
reclosable clamshell package 54, being molded, e.g., thermoformed,
vacuum formed, or vacuum thermoformed, in a three-dimensionally
recessed cavity formed in a mold 52 in which the flipper assembly
50 is disposed with at least part of the flipper arm 64 and/or base
62 helping form the feature in the molded component, e.g., package
54, during molding, e.g., thermoforming, vacuum forming, or vacuum
thermoforming, of the component, e.g., package 54, in the mold 52.
Such a flipper assembly 50 constructed in accordance with the
present invention is further configured so that a portion of the
flipper assembly 50, preferably the flipper arm 64, moves relative
to the base 62 and the mold 52 during demolding of the molded
component, e.g., molded package 54, during removal of the
component, e.g., package 54, from the cavity in the mold 52 after
molding of the component, e.g., package 54, has been completed.
[0076] As depicted in the drawing figures and discussed in more
detail herein, the flipper arm 64 is configured to be movable,
preferably pivotable, relative to at least the base 62 during
component demolding from a molding or forming position, e.g., first
position, toward a demolding position, e.g., second position,
disposed from the molding or forming position to facilitate
demolding of the component, e.g., package 54, from the mold 52. In
a preferred embodiment and method, the flipper arm 64 is configured
to be movable, preferably pivotable, relative to the base 62 and
the mold 52 between the molding or forming position, during which
the component, e.g., package 54, is molded in the mold 52, and the
demolding or component removal position, where the flipper arm 64
moves substantially in unison with a portion of the molded
component, package 54, in contact therewith during component
removal from the mold 52 thereby facilitating demolding or removal
of the component, e.g., package 54, from the mold 52 after molding
of the component, e.g. package 54, is finished. By the flipper arm
64 being moved, preferably being pivoted, relative to the base 62
and mold 52 and substantially in unison with a portion of the
molded component, package 54, in contact with the flipper arm 64
during demolding by separation of the molded component, e.g.,
package 54, from the mold 52, molded component removal from the
mold 52 is facilitated by preventing the flipper arm 64 from
obstructing molded component removal. By the flipper arm 64 moving,
preferably pivoting, relative to the base 62 and mold 52 during
demolding, it prevents any portion of the molded component, e.g.,
package 54, from getting caught or hung up on the flipper arm 64
during removal of the molded component, e.g., package 54, from the
mold 52 after molding of the component, e.g., package 54, is
completed.
[0077] As shown in the drawings and discussed in more detail
elsewhere herein, the flipper arm 64 is movably anchored to the
base 62 of the flipper assembly 50 by a pivot anchor that more
preferably is an elongate pivot pin 74 that extends through a
portion of the flipper arm 64 disposed in operable communication
with the base 62 in a direction transverse to the flipper arm 64
with at least a portion of the pivot pin 74 extending into a
portion of the base 62 on at least one and preferably both sides of
the flipper arm 64 defining a transverse flipper arm pivot axis
about which the flipper arm 64 pivots when moved between the
molding or forming position and the demolding or molded component
removal position. In a preferred flipper arm assembly embodiment
and method, the flipper arm 64 is disposed in a retracted position
when disposed in the molding or forming position, e.g., first
position, where at least a portion of the flipper arm 64 is
received, preferably nests, in part of the base 62 that preferably
is a flipper arm seating recess or pocket 107 formed in an outer or
top portion of the base 62 disposed distal to a bottom portion or
base of the base 62 that is disposed in contact with, e.g.,
grounded to, the mold 52. In such a preferred flipper arm assembly
embodiment and method, the flipper arm 64 is pivoted during
demolding away from the retracted position, e.g., away from the
molding or forming position, toward an extended position, e.g.,
second position, where at least a portion of the flipper arm 64
extends outwardly from and/or outwardly of the top portion of the
base 62 when the flipper arm 64 is urged to or toward the demolding
or molded component removal position by the molded component, e.g.,
package 54, being removed from the mold 52. When demolding is
finished and the molded component, e.g., package 54, is completely
detached from the mold 52, the flipper arm 64 automatically returns
to the retracted position thereby disposing the flipper arm 64 in
the molding or forming position with the flipper arm 64 preferably
received or nested in the recessed flipper arm seat 107 formed in
the base 62 readying the flipper arm assembly 50 and the mold 52 to
mold or form another component, e.g. package 54.
[0078] As also shown in the drawings and discussed in more detail
elsewhere herein, the flipper arm 64 is disposed in operative
cooperation with a mechanical biasing element that preferably is an
elongate coil spring 66 captured in tension that biases or urges
the flipper arm 64 to return to the molding or forming position
when displaced, e.g., pivoted, toward and/or to the demolding or
component removal position during demolding of a finished molded
component, e.g., package 54, from the mold 52. As also shown in the
drawings and discussed in more detail below, the mechanical biasing
element preferably is a coil spring 66 that has one end operatively
connected to part of the flipper arm 64 by one spring anchor, which
preferably is an elongate pin 78, e.g., first elongate spring
anchor pin 78, and has an opposite end operatively connected to
part of the base 62 by another spring anchor, which preferably also
is an elongate pin 76, e.g., second elongate spring anchor pin 76.
In light of the locations of the pins 76, 78 relative to the base
62 and the flipper arm 64, the spring 66 preferably extends and
retracts in a primarily, and more preferably in only in a linear
fashion. In a preferred embodiment and method, the one end of the
spring 66 that is anchored by anchor pin 76 to the base 62 is
anchored to ground because the base 62 is grounded to the mold 52
by being immovably mounted to the mold 52, such as by being fixed
to the mold 52 by one or more fasteners, e.g., bolts.
[0079] During molding of the component, e.g., package 54,
preferably by thermoforming, vacuum forming or vacuum
thermoforming, the spring 66 retains the flipper arm 64 in its
retracted molding or forming position where at least a portion,
preferably a substantial portion, of the flipper arm 64 is seated
in the recessed flipper arm seat 107 formed in the top or outer
portion of the base 62. While the flipper arm assembly 50 can be
configured so the entire flipper arm 64 can be retracted into the
recessed flipper arm seat 107 in the base 62, the flipper arm 64
and base 62 preferably are configured so that substantially all of
the flipper arm 64 is seated within the seat 107 except for an
undercut forming nose 134 of the flipper arm 64 located at a free
end of the flipper arm 64 that protrudes transversely outwardly
beyond or from an adjacent part of the upper base 62. Such an
undercut forming nose 134 extends outwardly into the cavity of the
mold 52 thereby forming a corresponding complementarily
three-dimensionally contoured or shaped finger or undercut in the
component, package 54, being molded in the mold 52.
[0080] When molding is completed, demolding of the component,
package 54, occurs to remove the finished molded component, e.g.,
finished molded package 54, from the cavity of the mold 52. In
separating the finished molded component, e.g., finished molded
package 54, from the mold 52 in removing it from the mold cavity, a
portion of the finished molded component, e.g., finished molded
package 54, in contact with a portion of the flipper arm 64 causes
the flipper arm 64 to pivot about pivot pin 74 outwardly away from
the mold 52 and mold cavity from the retracted molding or forming
position toward the demolding or component removal position where
at least the undercut forming nose 134 of the flipper arm 64
extends outwardly from the base 62, preferably until at least the
undercut forming nose 134 of the flipper arm 64 upwardly relative
to the base 62. As the flipper arm 64 is pivoted toward the
extended demolding or molded component removal position by the
finished molded component, e.g., finished molded package 54, being
pulled away from the mold cavity and mold 52 during demolding, an
angle between the portion of the finished molded component, e.g.,
finished molded package 54, in contact with the flipper arm 64 and
the flipper arm 64 reaches a release angle where the finished
molded component, e.g. finished molded package 54, disengages from
the flipper arm 64 without the flipper arm 64 changing the final
shape of the finished molded component, e.g., finished molded
package 54. When the finished molded component, e.g., finished
molded package 54, completely disengages from the flipper arm 64,
the spring 66 biases the flipper arm 64 in a primarily, and more
preferably a purely linear fashion, from at or adjacent the
extended demolding or component removal position toward the
retracted component forming or molding position causing the flipper
arm 64 to pivot about pin 74 until the flipper arm 64 is received
back in the recessed flipper arm seat 107 formed in the top or
outer portion of the base 62. When the flipper arm 64 is seated in
the recessed flipper arm seat 107, the flipper arm 64 is once again
disposed in the component forming or molding position, thereby
readying the flipper arm assembly 50 for another component molding
cycle to make another molded component.
[0081] A flipper assembly 50 of the present invention is configured
to retain the flipper arm 64 in the first position, the
thermoforming or molding position, and to return the flipper arm 64
back to the first position when demolding or removal of the molded
component, e.g., package 54, is completed. The flipper assembly 50
of the present invention also is configured to allow the flipper
arm 64 to be pivoted away from the first position, the
thermoforming or molding position, by part of the molded component,
e.g., package 54, during separation of the molded component, e.g.,
package 54, during demolding or removal of the molded component
from the mold after molding, e.g., thermoforming, of the molded
component is finished. The flipper arm assembly 50 of the present
invention is further configured to allow the flipper arm 64 to
return to the first position, the thermoforming or molding
position, upon complete disengagement of the molded component,
e.g., package 54, during demolding of the molded component from the
mold 52.
[0082] A flipper assembly 50 of the present invention is configured
with a spring 66 in tension that mechanically movably, e.g.,
pivotably, operatively connects or operably couples the flipper arm
64 to the base 62 with the spring 66 having a spring constant
sufficient to permit the flipper arm 64 to move, preferably rotate,
relative to the base 62 between the first position, the molding or
thermoforming position, during package molding or thermoforming,
and the second position, the demolding or finished mold component
removal position, in a primarily and more preferably solely linear
fashion during molded package removal. The flipper assembly 50 is
configured with such a spring 66 that has sufficient spring
constant, spring tension, or spring force to resiliently retain the
flipper arm 64 in the first position, the thermoforming or molding
position, and also resiliently urge the flipper arm 64 in a linear
fashion back towards the first position, the thermoforming or
molding position, after the flipper arm 64 is displaced by package
54 during removal of the formed or finished package 54 from the
cavity of the mold 52. The flipper assembly 50 also is configured
with such a spring 66 having sufficient spring constant, spring
tension, or spring force to allow a portion of the finished package
54 in contact with part of the flipper arm 64 to displace the
flipper arm 64, preferably by pivoting the flipper arm 64 relative
to the base 62 and mold 52 toward the second position, the
demolding position, by the finished package 54 separating away from
the mold 52 during demolding of the package 54 after thermoforming
of the package 54 is finished. The flipper assembly 50 is further
configured with such a spring 66 having sufficient spring constant,
spring tension or spring force to thereafter return the flipper arm
64 in a linear fashion back to the first position, the
thermoforming or molding position, when the portion of the package
54 in contact with the flipper arm 64 disengages or separates from
the flipper arm 64 during demolding of the finished package 54.
[0083] Understandably, the present invention has been described
above in terms of one or more preferred embodiments and methods. It
is recognized that various alternatives and modifications can be
made to these embodiments and methods that are within the scope of
the present invention. It is also to be understood that, although
the foregoing description and drawings describe and illustrate in
detail one or more preferred embodiments of the present invention,
to those skilled in the art to which the present invention relates,
the present disclosure will suggest many modifications and
constructions as well as widely differing embodiments and
applications without thereby departing from the spirit and scope of
the invention. The present invention, therefore, is intended to be
limited only by the scope of the appended claims.
* * * * *